Ingress resistant spargers

Abstract

An apparatus for distributing fluid in a medium. The apparatus includes an inlet conduit, and at least one nozzle comprising at least one outlet. The nozzle is fluidly connected to the inlet conduit. The nozzle distributes fluid into the medium in an outlet direction. The outlet direction at least partially opposes a direction of buoyant forces imposed on the fluid by the medium. Ingress of the medium into the apparatus is ameliorated by the formation of a cap in the outlet. A valve fluidly connected to the inlet conduit resists flow of the fluid in a backflow direction from the nozzle towards the valve.

Description

INGRESS RESISTANT SPARGERSTechnical Field

[0001] This invention relates to spargers. This invention may be applicable to hydrocarbon pyrolysis reactor systems, in particular for distributing hydrocarbon therein.Background

[0002] There is a general desire to refine hydrocarbons.

[0003] Hydrocarbon pyrolysis reactor systems that use molten media, such as molten metals and molten salts, crack hydrocarbons into smaller, industrially useful molecules such as hydrogen, olefins and the like. These systems are integral to the chemical and petrochemical industries, where the thermal decomposition of hydrocarbons is a fundamental process for producing a wide range of process chemicals and fuels.

[0004] Molten media serve dual roles in these reactors: as heat transfer agents and, in some cases, as catalysts that facilitate the pyrolysis reactions. The use of molten salts and metals facilitates uniform heat distribution, efficient heat transfer, and attainment of the high temperatures needed for pyrolysis.

[0005] The advantages of using molten media in hydrocarbon pyrolysis include improved heat management, higher thermal efficiencies, and enhanced product selectivity.

[0006] Spargers can be used to distribute hydrocarbons into the pyrolysis reactor. However, the use of spargers can result in a number of operational challenges. For example, the molten medium in the hydrocarbon pyrolysis reactor systems may enter the spargers if gaseous hydrocarbon flow fluctuates, reduces, or stops. This may resultin degradation of the spargers (e.g., blockage, loss of performance, or damage to the piping, valves, sensors, and equipment installed upstream of the pyrolysis reactor, and the like). This may lead to reliability problems in hydrocarbon pyrolysis reactors.

[0007] The aforementioned consequences can be ameliorated by controlling gas flow with control systems to provide a constant flow of gas at a constant pressure, however such control systems can be expensive. Such control systems would also need to be reliable and precise, which is also not always feasible.

[0008] There remains a need for improved spargers.

[0009] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.Summary

[0010] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, apparatus and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above- described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

[0011] One aspect of the invention provides an apparatus for distributing fluid into a medium, the apparatus comprising: an inlet conduit; at least one nozzle fluidly connected to the inlet conduit comprising one or more outlets, each outlet configured to distribute fluid into the medium in an outlet direction, wherein the outlet direction has a component direction that is co-directional with a direction of gravity; and at least one valve fluidly connected to the inlet conduit that is operable to resist flow of the fluid in a backflow direction from the nozzle towards the valve.

[0012] Another aspect of the invention provides an apparatus for distributing fluid into a medium, the apparatus comprising: an inlet conduit; at least one nozzle fluidly connected to the inlet conduit comprising one or more outlets, each outlet configured to distribute fluid into the medium in an outlet direction, wherein the outlet direction at least partially opposes a direction of buoyant force imposed on the fluid by the medium; and at least one valve fluidly connected to the inlet conduit that is operable to resist flow of the fluid in a backflow direction from the nozzle towards the valve.

[0013] In some embodiments, the apparatus is configured to direct all fluid received by the inlet conduit into the one or more outlets.

[0014] In some embodiments, the apparatus is configured to direct substantially all fluid received by the inlet conduit into the one or more outlets.

[0015] In some embodiments, the valve comprises a one-way valve or check valve. In some embodiments, the valve comprises a control valve. In some embodiments, the valve comprises both: (1) a one-way valve or check valve, and (2) a control valve.

[0016] In some embodiments, the control valve is upstream, in the backflow direction, of the one-way valve, or the control valve is downstream, in the backflow direction, of the one-way valve.

[0017] In some embodiments, the control valve is actuatable in response to signals from one or more backflow pressure sensors in the nozzles and / or the inlet conduit.

[0018] In some embodiments, the apparatus is configured to form a cap within the outlet by the fluid that resists ingress of the medium into the apparatus. The cap may form between an upper inlet threshold of the outlet and a lower inlet threshold of the outlet.

[0019] In some embodiments, the fluid is buoyant in the medium.

[0020] In some embodiments, the outlet direction forms an angle with a plane perpendicular to the direction of gravity. The angle may be between 1 ° and 90°. The angle may be 45°.

[0021] In some embodiments, a cross-sectional area of the outlet of the nozzle is substantially constant from where the outlet connects to a passageway of the nozzle to where the outlet distributes fluid into the medium.

[0022] In some embodiments, a cross sectional area of the outlet of the nozzle decreases from where the outlet connects to a passageway of the nozzle to where the outlet distributes fluid into the medium.

[0023] In some embodiments, the outlet comprises at least one pore.

[0024] In some embodiments, the fluid is distributed into a pyrolysis reactor. The medium may be one or more of a molten metal and a molten salt in the pyrolysis reactor. The nozzle may be situated adjacent to a bottom wall of the pyrolysis reactor. The nozzle may be situated adjacent to a side wall of the pyrolysis reactor.

[0025] In some embodiments, the fluid is a gas. In some embodiments, the fluid is a hydrocarbon. The hydrocarbon may be methane.

[0026] In some embodiments, the medium comprises a fermentation broth in a fermenter, and the fluid comprises oxygen.

[0027] In some embodiments, the medium comprises a molten metal in a degassing apparatus, and the fluid comprises an inert gas.

[0028] In some embodiments, the nozzle is encased within a shroud. The shroud may comprise one or more of: alumina, silicon dioxide (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), and zirconia.

[0029] In some embodiments, the fluid is at a temperature of between -30°C to 1600°C in the outlet.

[0030] In some embodiments, the fluid is at a temperature of between 5°C and 1200°C lower than a temperature of the medium.

[0031] In some embodiments, all of the components of the nozzle are stationary.

[0032] Another aspect of the invention provides a method of distributing a fluid in a medium, the method comprising: flowing the fluid into an inlet conduit fluidly connected to a nozzle comprising at least one outlet; distributing the fluid from the outlet in an outlet direction into the medium, wherein the outlet direction has a component direction that is co-directional with a direction of gravity; one or more of stopping, reducing, orperturbing the flow of the fluid; retaining at least some of the fluid in the outlet to form a cap; and resisting ingress of the medium into the nozzle with the cap.

[0033] Another aspect of the invention provides a method of distributing a fluid in a medium, the method comprising: flowing the fluid into an inlet conduit fluidly connected to a nozzle comprising at least one outlet; distributing the fluid from the outlet in an outlet direction into the medium, wherein the outlet direction at least partially opposes a direction of buoyant force imposed on the fluid by the medium; one or more of stopping, reducing, or perturbing the flow of the fluid; retaining at least some of the fluid in the outlet to form a cap; and resisting ingress of the medium into the nozzle with the cap.

[0034] In some embodiments, the methods may further comprise distributing all fluid received by the inlet conduit in the outlet direction. In some embodiments, the methods may further comprise distributing substantially all fluid received by the inlet conduit in the outlet direction.

[0035] In some embodiments, the methods may further comprise resisting flow of fluid in a backflow direction from the nozzle to the inlet conduit. Resisting the flow of fluid may comprise resisting flow of fluid with at least one valve. The valve may comprise a one-way valve or check valve. The valve may comprise a control valve. The valve may comprise both: (1) a one-way valve or check valve, and (2) a control valve.

[0036] In some embodiments, the control valve is upstream, in the backflow direction, of the one-way valve or check valve, or the control valve is downstream, in the backflow direction, of the one-way valve or check valve.

[0037] In some embodiments, the methods may further comprise actuating the control valve in response to signals from one or more backflow pressure sensors in the nozzles and / or the inlet conduit.

[0038] In some embodiments, the methods may further comprise maintaining the cap between an upper inlet threshold and a lower inlet threshold of the outlet.

[0039] In some embodiments, the medium is one or both of: a molten metal, and a molten salt. The fluid may be a gas. The fluid may be distributed in a pyrolysis reactor. The fluid may be a hydrocarbon. The hydroca bon may be methane.

[0040] In some embodiments, the fluid comprises oxygen, and the medium comprises fermentation broth in a fermenter.

[0041] In some embodiments, the fluid is the fluid comprises an inert gas, and the medium comprises molten metal in a degassing apparatus.

[0042] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.Brief Description of the Drawings

[0043] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

[0044] Figure 1 shows a hydrocarbon pyrolysis reactor system with a prior art sparger.

[0045] Figure 2A shows a horizontally oriented prior art sparger with a plurality of nozzles. Figure 2B shows a vertically oriented prior art sparger. Figure 2C shows a horizontally oriented prior art sparger.

[0046] Figure 3A shows a horizontally oriented prior art porous tube sparger. Figure 3B shows a vertically oriented prior art porous tube sparger. Figure 3C shows a porous disk sparger.

[0047] Figure 4A shows a sparger with a horizontal inlet conduit according to an example embodiment. Figure 4B is a nozzle according to an example embodiment.

[0048] Figure 5A shows a sparger with a vertical inlet conduit according to an example embodiment. Figure 5B shows a nozzle according to an example embodiment.

[0049] Figure 6A shows a porous sparger according to an example embodiment. Figure 6B shows an enlarged view of a porous sparger according to an example embodiment.

[0050] Figure 7A shows a porous sparger according to an example embodiment. Figure 7B shows an enlarged view of a porous sparger according to an example embodiment.

[0051] Figure 8A shows a sparger with a horizontal inlet conduit and a plurality of nozzles according to an example embodiment. Figure 8B is a cross sectional view of a sparger with a horizontal inlet conduit and a plurality of nozzles according to an example embodiment.

[0052] Figure 9 shows a sparger according to an example embodiment.Description

[0053] Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0054] Aspects of the invention include spargers with nozzles oriented such that fluid is distributed therefrom in a direction opposite to the buoyant force, thereby ameliorating fouling and degradation issues that are present in prior art spargers due to the retention of gas within the nozzle and the formation of a cap. An example application of such spargers is in the context of hydrocarbon pyrolysis reactors.

[0055] Throughout the following description, the word “sparger” should be understood as synonymous with the word “bubble generator”. A sparger introduces a fluid into a medium, typically (though not necessarily) in such a manner that the fluid forms bubbles in the medium.

[0056] Figure 1 shows a hydrocarbon pyrolysis reactor system 100. Hydrocarbon pyrolysis reactor system 100 employs a thermal cracking process to convert hydrocarbon feedstock (e.g., methane, natural gas) into product gas (e.g., hydrogen, olefins) and solid carbon. System 100 has a reactor 104 with an inlet 102.Hydrocarbons 103 are introduced into body 107 of reactor 104 containing medium 105 that is maintained at a high temperature suitable for thermal cracking. In some embodiments, medium 105 comprises molten metal and / or molten salt. Medium 105 can include catalysts to enhance the thermal cracking process, allowing for lower temperatures and quicker, more complete reactions.

[0057] Thermal energy is added to reactor 104 at different points to maintain medium 105 in a liquid state and at the desired temperature for thermal cracking.

[0058] Reactor 104 includes a prior art sparger 150 to inject hydrocarbon 103 in medium 105. Prior art sparger 150 creates bubbles B of hydrocarbon 103 within medium 105. As the feed of hydrocarbons 103 is fed into body 107 of reactor 104 adjacent to bottom wall 107B, it is heated by medium 105 and rises due to buoyancy and / or the motion of medium 105.

[0059] The feed of hydrocarbons 103 may be inconsistent. For example, the flow rate of hydrocarbons 103 may fluctuate, reduce, and / or stop. If the flow rate of hydrocarbons 103 fluctuates, reduces, and / or stops, there may be ingress of medium 105 in prior art sparger 150. Generally, in any case where the pressure of gas leaving prior art sparger150 is less than the pressure exerted by medium 105 on prior art sparger 150, there is a risk of ingress of medium 105.

[0060] Ingress may cause blockage and / or loss of performance of prior art sparger 150, for example due to solidification of medium 105 therewithin. Ingress may further result in damage to piping, valves, sensors, and other equipment installed upstream of prior art sparger 150. Ingress could also result in failure of prior art sparger 150, and / or reduce the operating lifetime of prior art sparger 150. In some embodiments, medium 105 is corrosive, and ingress of medium 105 into prior art sparger 150 may corrode prior art sparger 150 and / or components upstream of prior art sparger 150. By way of example, in embodiments where medium 105 is molten metal, the molten metal could corrode prior art sparger 150 and / or components upstream of prior art sparger 150.

[0061] Figure 2A shows a horizontally oriented prior art sparger 150A with a plurality of nozzles. In horizontally oriented prior art sparger 150A, longitudinal axis 105A-1 is oriented perpendicular to the direction of gravity (i.e., the direction indicated by arrow g). Figure 2B shows a vertically oriented prior art sparger 150B. In Figure 2B, longitudinal axis 105B-1 is oriented parallel to the direction of gravity. Figure 2C shows a horizontally oriented prior art sparger 150C. In Figure 2C, longitudinal axis 105C-1 is oriented perpendicular to the direction of gravity. In each of prior art spargers 150A, 150B, and 150C, if the inlet flow of hydrocarbons 103 is reduced, stopped, or fluctuated, there is a risk of ingress of medium 105. This is because there is no resistance to medium 105 flowing into any of prior art spargers 150A, 150B, and 150C. Damage from ingress of medium 105 may happen because of any one of: a reduced ability of buoyant hydrocarbon 103 to exhaust from prior art spargers 150A, 150B, and / or 150C; corrosion of spargers 150A, 150B, and / or 150C and / or components upstream of spargers 150A, 150B, and 150C; and / or damage from solidification of medium 105 in spargers 150A, 150B, and 150C.

[0062] Figure 3A shows a prior art horizontally oriented porous tube sparger 150D. In porous tube sparger 150D, a longitudinal axis of porous tube 150D-1 is oriented perpendicular to the direction of gravity (i.e., the direction indicated by arrow g). Figure 3B shows a prior art vertically oriented porous tube sparger 150E. In vertically oriented porous tube sparger 150E, a longitudinal axis of porous tube 150E-1 is oriented parallel to the direction of gravity. Figure 3C shows a prior art porous disc sparger 150F. In each of spargers 150D, 150E, and 150F, there is a risk of ingress of medium 105 therewithin when a flow of hydrocarbons 103 stops, fluctuates, or slows down.

[0063] Figure 4A shows a sparger 200 according to an example embodiment. Figure 4B is a schematic of nozzle 204 according to an example embodiment. Except where the context clearly requires otherwise, those elements shown in Figure 4A and Figure 4B that have been identified with references that share the same numbers as elements of Figures 1 to 3 have the same or similar functions as described with respect to Figures 1 to 3.

[0064] Sparger 200 comprises inlet conduit 202 and at least one nozzle 204. Inlet conduit 202 provides a fluid path for hydrocarbon 103 to nozzle 204. Sparger 200 further comprises at least one valve, which can comprise control valve 206 and / or one- way valve 208. Nozzle 204 is fluidly connected to inlet conduit 202.

[0065] In some embodiments, nozzle 204 is encased within a refractory material that prevents corrosion and / or provides thermal resistance against medium 105.

[0066] As shown in Figure 4B, nozzle 204 comprises at least one outlet 210. In the example embodiment shown in Figure 4B, there are two outlets, namely outlet 210A and outlet 210B. Outlet 210 is fluidly connected to inlet conduit 202 via passageway 212. In other embodiments, one outlet, or more than two outlets, may be present. In some embodiments, including the embodiment illustrated in Figure 4B, the cross- sectional area of outlet 210 is substantially constant from where outlet 210 connects to passageway 212 to where outlet 210 distribut fluid into medium 105. In someembodiments (not depicted), the cross sectional area of outlet 210 narrows from where outlet 210 connects to passageway 212 to where outlet 210 distributes fluid into medium 105.

[0067] Outlet 210 distributes fluid, for example hydrocarbons 103, from outlet 210 in an outlet direction indicated by arrow 214. Outlet direction 214 is angled and / or askew relative to the direction of gravity indicated by arrow g. Outlet direction 214 forms an angle Q with a plane (e.g., a plane parallel to line 215) perpendicular to the direction of gravity. Outlet direction 214 can be broken into at least two component directions indicated by arrows 214A and 214B. Component direction 214A is perpendicular to the direction of gravity. Component direction 214B is parallel to, and in the same direction as the direction of gravity (i.e. , component direction 214B is co-directional with the direction of gravity).

[0068] In other words, outlet direction 214 at least partially opposes the direction of buoyant forces imposed on distributed hydrocarbon 103 by medium 105. The direction of the buoyant force is indicated by arrow Fb.

[0069] In some embodiments, sparger 200 is configured such that all fluid received by inlet conduit 202 is directed to outlets 210 for distribution into the medium in outlet direction 214. In some embodiments, sparger 200 is configured such that substantially all fluid received by inlet conduit 202 is directed to outlets 210 for distribution into the medium in outlet direction 214. As used herein, the phrase “substantially all” means 95% or more.

[0070] Angle 0 can vary. In some embodiments, angle 0 is between 1 ° and 90° inclusive, including any value therebetween, e.g., 5°, 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, and 90°.

[0071] The specific configuration of nozzle 204 (i.e., with an outlet direction 214 that has a component direction in the same direction o gravity) is advantageous as itameliorates the ingress of medium 105 into nozzle 204. When the flow of hydrocarbon 103 fluctuates, reduces, or stops, ingress of medium 105 (indicated by arrow 103A) is ameliorated and / or prevented by the formation of cap 216. In Figure 4B, cap 216 comprises hydrocarbon 103 that has not been distributed from nozzle 204. Cap 216 forms because hydrocarbon 103 is buoyant in medium 105. Ameliorating ingress of medium 105 is desirable as it reduces fouling and degradation issues in sparger 200. Ameliorating ingress of medium 105 in nozzle 204 is also desirable as it limits the extent to which hydrocarbon 103 reacts within nozzle 204.

[0072] In some embodiments, cap 216 forms at a point between upper inlet threshold 204U and lower inlet threshold 204L of outlet 210. Lower inlet threshold 204L is the lowest point on outlet 210 at which cap 216 is able to form without exhausting into medium 105 (shown by low cap fluid line 216L). Upper inlet threshold 204U is the highest point on outlet 210 at which cap 216 is able to form without ingress of medium 105 into inlet conduit 202 (via passageway 212, shown by upper cap fluid line 216U). In some embodiments, surface tension may cause cap 216 to form an arcuate cross section within outlet 210, rather than a linear cross section as shown in Figure 4B.

[0073] Valve 208 is fluidly connected to inlet conduit 202. Valve 208 is a one-way valve, check valve, or similar device that resists flow of hydrocarbon 103 in a backflow direction from nozzle 204 (indicated by arrow 103B in Figure 4A and Figure 4B). Valve 208 is advantageous as it facilitates the maintenance of cap 216. When flow of hydrocarbon 103 fluctuates, reduces, or stops, the static fluid pressure of medium 105 exerts a pressure on cap 216. Without valve 208 resisting flow in the backflow direction, the static fluid pressure may result in cap 216 retreating from outlet 210A into passageway 212 and / or inlet conduit 202. The inclusion of valve 208 maintains hydrocarbon 103 within sparger 200 thereby maintaining the presence of cap 216.

[0074] In some embodiments a control valve 206 may be downstream (in the backflow direction) of valve 208. Control valve 206 may adjust or stop the flow of fluid flowing into inlet conduit 202. Control valve 206 may also cilitate the maintenance of cap 216.Control valve 206 may resist flow in the backflow direction. By resisting flow in the backflow direction, control valve 206 may resist the static fluid pressure acting on cap 216 from medium 105, thereby maintaining the presence of cap 216.

[0075] Although in the depicted embodiment of Figure 4A control valve 206 is downstream (in the backflow direction) of valve 208, in some embodiments control valve 206 may be upstream (in the backflow direction) of valve 208.

[0076] In some embodiments valve 208 may be absent and only control valve 206 may be present to resist flow of hydrocarbon 103 in a backflow direction from nozzle 204. In such embodiments, closing of control valve 206 may be actuated by signals from one or more sensors in nozzles 204 and / or inlet conduit 202 that sense backflow pressure.

[0077] In some embodiments, hydrocarbon 103 is distributed into medium 105 at a temperature lower than medium 105. For example, hydrocarbon 103 may be distributed into medium 105 at a temperature of 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 60°C, 70°C, 80°C, 90°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, 500°C, 550°C, 600°C, 650°C, 700°C, 750°C, 800°C, 850°C, 900°C, 950°C, 1000°C, 1100°C, or 1200°C lower than medium 105.

[0078] In some embodiments, hydrocarbon 103 is distributed into medium 105 at a temperature of between -30°C and 1600°C (when measured at outlet 210), including any value therebetween, for example -30°C, -25°C, -20°C, -15°C, -10°C, -5°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 60°C, 70°C, 80°C, 90°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, 500°C, 550°C, 600°C, 650°C, 700°C, 750°C, 800°C, 850°C, 900°C, 950°C, 1000°C, 1100°C, 1200°C, 1300°C, 1400°C, 1500°C, or 1600°C.

[0079] As shown in Figure 4A, sparger 200 is adjacent to bottom wall 107B of reactor 104. In some embodiments sparger 200 may be situated elsewhere on body 107, for example adjacent a side wall (e.g., adjacent side wall 107S). In some embodiments,there may be a plurality of spargers 200 situated at multiple different locations on body 107.

[0080] Figure 5A shows a sparger 220 according to an example embodiment. Figure 5B is a nozzle 204 according to an example embodiment. Except where the context clearly requires otherwise, those elements shown in Figure 5A and Figure 5B that have been identified with references that share the same numbers as elements of Figure 4A and Figure 4B have the same or similar functions as described with respect to Figure 4A and Figure 4B.

[0081] As shown in Figure 5A, nozzle 204 is encased in shroud 218. Shroud 218 prevents corrosion of nozzle 204 by medium 105 and / or provides heat resistance against medium 105. In some embodiments shroud 218 comprises one or more of: alumina, silicon dioxide (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), and zirconia.

[0082] As shown in Figure 5B, nozzle 204 comprises four outlets 210, i.e., outlet 210A, outlet 210B, outlet 210C, and outlet 210D. As described with respect to Figure 4B, cap 216 forms at a point between upper inlet threshold 204U and lower inlet threshold 204L of outlet 210A. Lower inlet threshold 204L is the lowest point on outlet 210A at which cap 216 is able to form without bubbling into medium 105. Upper inlet threshold 204U is the highest point on outlet 210A at which cap 216 is able to form without ingress of medium 105 into inlet conduit 202 (via passageway 212). In nozzle 204, each of outlets 210A, 210B, 210C, and 210D have a separate upper inlet threshold 204U and lower inlet threshold 204L. Separate caps 216 may form in each of outlets 210A, 210B, 210C, and 210D to resist ingress of medium 105 in passageway 212.

[0083] Figure 6A shows a sparger 230 according to an example embodiment. Figure 6B shows a close-up view of sparger 230 according to an example embodiment. Except where the context clearly requires otherwise, those elements shown in Figure 6A and Figure 6B that have been identified with references that share the same numbers aselements of Figures 4 to 5 have the same or similar functions as described with respect to Figures 4 to 5.

[0084] Sparger 230 comprises a porous tube. Sparger 230 further comprises a nozzle 204, which in Figure 6 comprises a plurality of outlets, namely pore outlets 21 OP (visible in Figure 6B). In the embodiment shown in Figure 6A, longitudinal axis 230X of sparger 230 forms an angle a with a plane perpendicular to the direction of gravity. Angle a can vary from 1 ° to 90°. In the embodiment shown in Figure 6A, top 230T and sides 230S (defined relative to the direction of gravity) of sparger 230 are covered such that hydrocarbon 103 is distributed only from bottom 230B of sparger 230. In alternative embodiments, pores are absent on top 230T and sides 230S (defined relative to the direction of gravity) of sparger 230 such that hydrocarbon 103 is distributed only from bottom 230B of sparger 230.

[0085] As shown in Figure 6B, outlet direction 214 in sparger 230 is normal to bottom 230B of sparger 230. Arrow 214 has a component direction that is in the same direction as the direction of gravity, as indicated by component direction 214B. Outlet direction 214 at least partially opposes the direction of buoyant forces imposed on distributed hydrocarbon 103 by medium 105. This has the aforementioned advantage of forming a cap 216 upon cessation, perturbation and / or reduction in flow of hydrocarbon 103, for example at low cap fluid line 216L.

[0086] In some embodiments, sparger 230 is configured such that all fluid received by inlet conduit 202 is directed to outlets 210 for distribution into the medium in outlet direction 214. In some embodiments, sparger 230 is configured such that substantially all fluid received by inlet conduit 202 is directed to outlets 210 for distribution into the medium in outlet direction 214.

[0087] In some embodiments, a conduit is embedded within sparger 230 to facilitate distribution of hydrocarbon 103 across bottom 230B of sparger 230.

[0088] Figure 7A shows a sparger 240 according to an example embodiment. Figure 7B shows a close-up view of sparger 240 according to an example embodiment. Except where the context clearly requires otherwise, those elements shown in Figure 7 that have been identified with references that share the same numbers as elements of Figures 4 to 6 have the same or similar functions as described with respect to Figures 4 to 6. Hydrocarbon 103 is exhausted from bottom 240B of sparger 240. Sparger 240 is similar to sparger 230 except that angle a is zero (i.e., longitudinal axis 240X is perpendicular to the direction of gravity).

[0089] As visible in Figure 7A, inlet conduit 202 is adjacent middle 240M of sparger 240. In some embodiments, inlet conduit 202 may be situated in a different location on sparger 240, for example adjacent to side 240S of sparger 240.

[0090] Analogous to sparger 230, in some embodiments a conduit is embedded within sparger 240 to facilitate distribution of hydrocarbon 103 across bottom 240B of sparger 240.

[0091] Figure 8A shows a sparger 250 according to an example embodiment. Figure 8B is a cross sectional view of sparger 250 at section 252. Except where the context clearly requires otherwise, those elements shown in Figure 8A and Figure 8B that have been identified with references that share the same numbers as elements of Figures 4 to 7 have the same or similar functions as described with respect to Figures 4 to 7.

[0092] In Figure 8A, inlet conduit 202 has a longitudinal axis 254 that is perpendicular to the direction of gravity indicated by arrow g. A plurality of nozzles 204 are fluidly connected to inlet conduit 202.

[0093] As shown in Figure 8B, each nozzle 204 comprises an outlet 210 configured to distribute hydrocarbon 103 in outlet direction 214. Outlet direction 214 has a component direction 214B that is in the same direction as gravity. Outlet direction 214 at least partially opposes the direction of buoyant forces imposed on distributed hydrocarbon 103 by medium 105. Upon cessation, perturbation, and / or reduction in flow ofhydrocarbon 103, cap 216 forms within nozzle 204 thereby ameliorating the ingress of medium 105 (not shown in Figure 8A and Figure 8B). In some embodiments, cap 216 forms between lower inlet threshold 204L of nozzle 204 and upper inlet threshold 204U of nozzle 204.

[0094] Sparger 250 may be simpler to manufacture relative to sparger 200 and sparger 220. For example, manufacturing a refractory shroud (e.g., shroud 218) for sparger 250 may be less complex than manufacturing a refractory shroud for sparger 200 and sparger 220 due to the complex shape of nozzles 204 on sparger 200 and sparger 220.

[0095] Sparger 250 may additionally or alternatively have improved mechanical integrity relative to sparger 200 and sparger 220 due to the less intricate shape of nozzles 204 on sparger 250 relative to nozzles 204 on sparger 200 and sparger 220.

[0096] Figure 9 is a sparger 260 according to an example embodiment. Except where the context clearly requires otherwise, those elements shown in Figure 9 that have been identified with references that share the same numbers as elements of Figure 4 to 8 have the same or similar functions as described with respect to Figures 4 to 8.

[0097] In Figure 9, sparger 260 distributes hydrocarbon 103 into medium 105 at angle 0 relative to a plane perpendicular to the direction of gravity (e.g., a plane parallel to line 262).

[0098] As shown in Figure 9, sparger 260 is adjacent to side wall 107S of reactor 104.

[0099] As already mentioned, spargers as described herein may have application beyond pyrolysis reactors. For example, spargers as described herein may have application in the context of fermenters, wherein the fluid to be distributed comprises oxygen and wherein the medium in which the fluid is distributed is the fermentation broth. By way of further example, spargers as described herein may have application in the context of wastewater treatment. Sparger s described herein may also haveapplication in the context of bioreactors, bubble columns, fluidized beds, fixed beds, column flotations, aeration, and direct steamers. Spargers as described herein may also have application in the context of degassing in the smelting industry (and in such an application, medium 105 would be molten metal in a degassing apparatus and the sparger may distribute an inert gas into the medium).

[0100] Where a component (e.g., sparger, outlet, nozzle, inlet conduit, one-way valve, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.

[0101] Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and / or acts with equivalent features, elements and / or acts; mixing and matching of features, elements and / or acts from different embodiments; combining features, elements and / or acts from embodiments as described herein with features, elements and / or acts of other technology; and / or omitting combining features, elements and / or acts from described embodiments.

[0102] Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments.Embodiments of the invention may include zero, any one or any combination of two or more of such features. All possible combinati s of such features are contemplated bythis disclosure even where such features are shown in different drawings and / or described in different sections or paragraphs. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible).

[0103] It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

CLAIMS:1 . An apparatus for distributing fluid into a medium, the apparatus comprising: an inlet conduit; at least one nozzle fluidly connected to the inlet conduit comprising one or more outlets, each outlet configured to distribute fluid into the medium in an outlet direction, wherein the outlet direction has a component direction that is co-directional with a direction of gravity; and at least one valve fluidly connected to the inlet conduit that is operable to resist flow of the fluid in a backflow direction from the nozzle towards the valve.

2. An apparatus for distributing fluid into a medium, the apparatus comprising: an inlet conduit; at least one nozzle fluidly connected to the inlet conduit comprising one or more outlets, each outlet configured to distribute fluid into the medium in an outlet direction, wherein the outlet direction at least partially opposes a direction of buoyant force imposed on the fluid by the medium; and at least one valve fluidly connected to the inlet conduit that is operable to resist flow of the fluid in a backflow direction from the nozzle towards the valve.

3. The apparatus as defined in any one of the preceding claims (or any other claim herein) configured to direct all fluid received by the inlet conduit into the one or more outlets.

4. The apparatus as defined in any one of the preceding claims (or any other claim herein) configured to direct substantially all fluid received by the inlet conduit into the one or more outlets.

5. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises a one-way valve or check valve.

6. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises a control valve.

7. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises both: (1) a one-way valve or check valve, and (2) a control valve.

8. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein: the control valve is upstream, in the backflow direction, of the one-way valve; or the control valve is downstream, in the backflow direction, of the one-way valve.

9. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the control valve is actuatable in response to signals from one or more backflow pressure sensors in the nozzles and / or the inlet conduit.

10. The apparatus as defined in any one of the preceding claims (or any other claim herein) configured to form a cap within the outlet by the fluid that resists ingress of the medium into the apparatus.11 . The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the cap forms between an upper inlet threshold of the outlet and a lower inlet threshold of the outlet.

12. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is buoyant in the medium.

13. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the outlet direction forms an angle with a plane perpendicular to the direction of gravity.

14. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the angle is between 1 ° and 90°.

15. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the angle is 45°.

16. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein a cross-sectional area of the outlet of the nozzle is substantiallyconstant from where the outlet connects to a passageway of the nozzle to where the outlet distributes fluid into the medium.

17. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein a cross sectional area of the outlet of the nozzle decreases from where the outlet connects to a passageway of the nozzle to where the outlet distributes fluid into the medium.

18. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the outlet comprises at least one pore.

19. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is distributed into a pyrolysis reactor.

20. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the medium is one or more of a molten metal and a molten salt in the pyrolysis reactor.21 . The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the nozzle is situated adjacent to a bottom wall of the pyrolysis reactor.

22. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the nozzle is situated adjacent to a side wall of the pyrolysis reactor.

23. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is a gas.

24. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is a hydrocarbon.

25. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the hydrocarbon is methane.

26. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein:the medium comprises a fermentation broth in a fermenter; and the fluid comprises oxygen.

27. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein: the medium comprises a molten metal in a degassing apparatus; and the fluid comprises an inert gas.

28. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the nozzle is encased within a shroud.

29. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the shroud comprises one or more of: alumina, silicon dioxide (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), and zirconia.

30. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is at a temperature of between -30°C to 1600°C in the outlet.31 . The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is at a temperature of between 5°C and 1200°C lower than a temperature of the medium.

32. The apparatus as defined in any one of the preceding claims (or any other claim herein) wherein all components of the nozzle are stationary.

33. A method of distributing a fluid in a medium, the method comprising: flowing the fluid into an inlet conduit fluidly connected to a nozzle comprising at least one outlet; distributing the fluid from the outlet in an outlet direction into the medium, wherein the outlet direction has a component direction that is co-directional with a direction of gravity; one or more of stopping, reducing, or perturbing the flow of the fluid; retaining at least some of the fluid in the outlet to form a cap; and resisting ingress of the medium into the zzle with the cap.

34. A method of distributing a fluid in a medium, the method comprising: flowing the fluid into an inlet conduit fluidly connected to a nozzle comprising at least one outlet; distributing the fluid from the outlet in an outlet direction into the medium, wherein the outlet direction at least partially opposes a direction of buoyant force imposed on the fluid by the medium; one or more of stopping, reducing, or perturbing the flow of the fluid; retaining at least some of the fluid in the outlet to form a cap; and resisting ingress of the medium into the nozzle with the cap.

35. The method as defined in any one of the preceding claims (or any other claim herein) further comprising distributing all fluid received by the inlet conduit in the outlet direction.

36. The method as defined in any one of the preceding claims (or any other claim herein) further comprising distributing substantially all fluid received by the inlet conduit in the outlet direction.

37. The method as defined in any one of the preceding claims (or any other claim herein) further comprising resisting flow of fluid in a backflow direction from the nozzle to the inlet conduit.

38. The method as defined in any one of the preceding claims (or any other claim herein) further comprising resisting flow of fluid in the backflow direction with at least one valve.

39. The method as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises a one-way valve or check valve.

40. The method as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises a control valve.41 . The method as defined in any one of the preceding claims (or any other claim herein) wherein the valve comprises both: (1) a one-way valve or check valve, and (2) a control valve.

42. The method as defined in any one of the preceding claims (or any other claim herein) wherein: the control valve is upstream, in the backflow direction, of the one-way valve or check valve; or the control valve is downstream, in the backflow direction, of the one-way valve or check valve.

43. The method as defined in any one of the preceding claims (or any other claim herein) further comprising actuating the control valve in response to signals from one or more backflow pressure sensors in the nozzles and / or the inlet conduit.

44. The method as defined in any one of the preceding claims (or any other claim herein) further comprising maintaining the cap between an upper inlet threshold and a lower inlet threshold of the outlet.

45. The method as defined in any one of the preceding claims (or any other claim herein) wherein the medium is one or both of: a molten metal, and a molten salt.

46. The method as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is a gas.

47. The method as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is distributed in a pyrolysis reactor.

48. The method as defined in any one of the preceding claims (or any other claim herein) wherein the fluid is a hydrocarbon.

49. The method as defined in any one of the preceding claims (or any other claim herein) wherein the hydrocarbon is methane.

50. The method as defined in any one of the preceding claims (or any other claim herein) wherein: the fluid comprises oxygen; and the medium comprises fermentation broth in a fermenter.51 . The method as defined in any one of the preceding claims (or any other claim herein) wherein: the fluid comprises an inert gas; and the medium comprises molten metal in a degassing apparatus.

52. An apparatus having any combination or sub combination of features or elements as described herein.

53. A method comprising any step, act, combination of steps and / or acts or sub combination of steps and / or acts as described herein.

Images